Operating instructions

airtelligence PROVIS control

for several compressors

www.boge.com
 Operating instructions
airtelligence PROVIS

BOGE KOMPRESSOREN
Postfach 10 07 13
33507 Bielefeld

Otto-Boge-Straße 1-7
33739 Bielefeld

Phone: +49 5206 601-0

Fax: +49 5206 601-200
Mail: [email protected]
Net: www.boge.com

Issue: 11 / 2010
No. 596.1033.01
Nominal price: € 5,00

BOGE airtelligence PROVIS Page I

Index

Index

Part 1: 1.1 General safety instructions ........................................................... 1

General Safety instructions for compressor operation ................................... 1
Safety instructions for maintenance and repair of the compressor... 1
Introduction ....................................................................................... 2
Intended use ..................................................................................... 2
Inadmissible use ............................................................................... 3
Transport damage ............................................................................ 3
Customer service.............................................................................. 3
Installation and adjustment ............................................................... 4

BOGE airtelligence PROVIS Page III

General 1.1 General safety instructions

Part 1: General 1.1 General safety instructions

Attention!
Nonobservance of the following safety instructions may lead to injuries and
damage to the control. Also observe the generally valid safety and accident
prevention regulations in addition to the information in these operating in-
structions!

Safety instructions for 1. Ensure that no commissioning and maintenance work on the controlis un-
compressor operation dertaken until these operating instructions are understood.
2. Only use the control for its intended use, as described in these operating
instructions.
3. The owner must ensure:
– that only appropriately trained and authorized personnel work on this
control,
– that the operating, maintenance and repair personnel has been made
fully familiar with all safety instructions, and that they are being ob-
served,
– that the control is only operated in a safe operating condition.
4. Only operate the compressor using the additional equipment (options) rec-
ommended or authorized by the manufacturer.
5. Never start the control when one or serveral parts (e.g. cable, plug) are
damaged, when not in perfect working order, when damage is detected or
suspected.

Safety instructions for 1. Ensure that maintenance work is only carried out by appropriately trained
maintenance and repair persons.
of the compressor 2. Ensure that setting work, malfunction rectification and repair is only carried
out by qualified electricians (see DIN VDE 0100 or DIN EN 60204-1 / VDE
0113-1:2007).
3. Prior to maintenance or repair work:
– Switch off the main switch.
– Check that no parts are under voltage.
4. Work on voltage carrying parts and devices are not permitted. Exceptions
are governed by the appropriate regulations, e.g. DIN VDE 0105.
5. Only use original spare parts, compressor oils and operating materials re-
leased by BOGE during repair or maintenance.

BOGE airtelligence PROVIS Page 1

General 1.1 General safety instructions

Introduction The purpose of these operating instructions is to familiarize the user with the
function and all application possibilities of the control.
These operating instructions contain important information on how to operate
several compressors safely, economically and according to intended use, with
the aid of an MCS control.
Observing these operating instructions will assist in avoiding danger, to re-
duce repair costs and down times and to increase the reliability and service life
of the compressors.
It contains important information concerning the required parameters and set-
tings, and assists in case of malfunctions.
The operating instructions must be available to the control and compressor op-
erating personnel at the place of operation, at all times.
The operating instructions must be carefully read and applied by all persons
engaged to undertake the following work on the compressor:
– Operation, including fault rectification,
– Commissioning.

Intended use This BOGE multiple system control including its options is intended for the
control of several screw and piston compressors.
It may only be operated and adjusted by trained and authorised people.

Requirements for compressors to be controlled:

If the master control is ordered with compressors, we install the interface in the
compressors in the factory (forced option). If the compressors are already
installed, it will be necessary to meet the requirements for the master control.
These are normally:
1. A potential-free contact "Ready" (2 terminals).
2. Two terminals in series with the pressure switch installed in the compres-
sor.
3. A potential-free contact "Operation" (2 terminals).
4. A potential-free contact "Fault" (2 terminals).
For compressors with proportional control or frequency control please con-
tact BOGE.

Attention!
Care must be taken with other makes; always obtain approval from the fac-
tory.

Page 2 BOGE airtelligence PROVIS

General 1.1 General safety instructions

Inadmissible use This BOGE control is not explosion protected.

Do not operate in explosive areas!

Attention!
The following is not permitted:
– Exceeding or going below the specified operating voltages.
– Operation of the control by unauthorized or untrained persons.
– Connection of unsuitable compressors.
– Excessive room temperatures > 45°C.

Transport damage BOGE does not accept any liability for breakage or transport damage. Please
inspect the compressor immediately after delivery and direct damage claims
to the last haulier - even when the packing is not damaged! To safeguard
claims against the haulier we recommend leaving the machine, devices and
packing material in the same condition as they were in when the damage was
detected.
In the event of any other complaints, please inform us within six days after
arrival of the delivery.

Customer service The BOGE customer service is, of course, at your disposal. Please contact us
on:
Telephone: +49 52 06 / 6 01-0
To avoid delays, always specify the following details about your control:
1. Software version
2. Circuit diagram number
3. Job number
4. Machine number
5. Type
6. Year of manufacture

Attention!
Only BOGE service technicians or persons authorized by BOGE in writing
may repair or alter the control during the warranty period. Otherwise all war-
ranty claims will expire!

BOGE airtelligence PROVIS Page 3

General 1.1 General safety instructions

Installation and – The electronic pressure sensor must always be fitted verticaly (plug up-
adjustment wards) on the common receiver or pipelines and free of condensate water.
– If the air is damp (e.g. system without dryer), it will be necessary to verti-
cally install between the muff and pressure sensor a 150 mm pipe.
– The cutout point of the pressure switches of the individual compressors
must be set at least 0.2 bar higher that the upper cutout point of the master
control.

Attention!
The maximum operating pressure of the individual compressors may not be
exceeded.
– The pressure switches of the compressors are only used to allow opera-
tion in the event the master control fails.

Attention!
In the adjustment sequence the sub-menu "Pressure thresholds" must first
be checked and adjusted; thereafter the sub-menus general parameters;
"Compressor data" must be adjusted in this order.
– These operating instructions are only valid in conjunction with the appro-
priate circuit diagram.
– Instructions for making adjustments are given in the individual chapters.

Caution: High voltage!

Commissioning, adjustment, troubleshoorting and repairs may only be per-
formed by qualified electricians (see DIN VDE 0100, DIN EN 60204-1 / VDE
0113-1:2007 and DIN VDE 105).

Page 4 BOGE airtelligence PROVIS

airtelligence PROVIS

Operation manual

V 3.0...-12-2009
 airtelligence PROVIS - combines compressors of different sizes to an optimum unit

Almost the best strategy to save energy

m³/min
Load energy saving

25

unlo
Load
Energy

ad E
n er
25

gy
25 - only program the compressor capacities
- set the common pressure switch points
- mount the pressure transducer
- connect the cables
13
The compressors will be controlled by the real air con-
sumption
Within only 1 pressure difference for all compressors
7

Pmax

Pmin

For program version and serial number press ◄►

 1

SUMMARIES

TEIL 1 airtelligence PROVIS

Page 1 Summaries
Page 2 Functional description
Page 3 Display and key control

VARIABLE SPEED COMPRESSOR

Page 4 Control and interpretation of regulated compressors
Page 5 Configuration of regulation range and regulation buffer
Page 6 Minimum flow rate and remote pressure supply
Page 7 Station with 2 variable speed compressors

PROGRAMMING COMPRESSOR CONTROL

Page 8 Programming load / unload compressors
Page 9 Programming variable speed compressors
Page 10 Programming pressure and rank profiles
Page 11 Programming of analog inputs of airtelligence PROVIS
Page 12 Programming analog and digital inputs of connection modules (17-24)
Page 13 Digital input and analog output on connection module (17-24)

REAL TIME CLOCK

Page 14 Programming real time clock
Page 15 Clock programming notes

STATUS DATA and COMMISIONING

Page 16 Status data of compressors and connection modules
Page 17 Display features
Page 18 IP-addresse and network settings
Page 19 Commisioning and switching functions

PART 2 Measurements, configuration and connection schematics

Page 22 Operating the housing
Page 23 Measurement of airtelligence PROVIS
Page 24 Connection and termina plan
Page 25 Connection scheme
Page 26 RS-485 connection scheme
Page 27 Connection module configuration and measurement
Page 28 Digital and analog inputs of connection module
Page 29 Compressor connection load / unload
Page 30 Compressor connection with remote / local function
Page 31 Analog inputs on connection module
Page 32 Analog output on connection module
Page 33 Digital IN and OUT on airtelligence PROVIS
Page 34 Analog IN and OUT on airtelligence PROVIS

PART 3: OPTION: only if airtelligence PROVIS is built in metal housing

Page 36 Power supply, key switches, RS-485
Page 37 Connection of analog inputs / outputs
Page 38 Connection digital outputs
Page 39 Connection digital inputs
Page 40 Part List
Page 41 Arrangement Diagram

PART 4: Connection module Typ 4700 (grey)

Page 43 Configuration connection module
Page 44 Mesurement of connection module
Page 45 RS-485 connection scheme
 2

FUNCTIONAL DESCRIPTION

AIRTELLIGENCE PROVIS combines compressors of different sizes

to an optimum unit which automatically adapts to the production based on the current compressed air consumption.
It is made sure that it is always the most efficient compressor combination which generates the compressed air
necessary for production, independent of the manufacturer and the performance. The system pressure remains
within the smallest limits. It is seen that the costs are kept as low as possible. The compressor performances and a
common pressure difference are programmed in for all the compressors. Based on this information,
AIRTELLIGENCE PROVIS permanently calculates the current compressed air consumption and the volume of the
compressed air system. The self-learning 8-fold calculation depth makes it possible to adapt the compressors to
the changes in consumption in a dynamic way.

Automatic compressor change as per compressed air consumption

If all the compressors are on the same rank, they are working fully automatically and based on real air
consumption. The priority of the compressors is adapted to the production process in real time with a useful
hysterisis calculation. It is always the compressor combination with the lowest cycle rates which is running and thus
with the lowest idle times. Big compressors are only running when needed. The smaller compressors are running
under load instead of idling the big compressors. The compressors auto-regulate the motor start limitations.

The status of the compressors is constantly monitored.

If a running compressor displays a malfunction within the pressure range or is switched off for service, its
performance is taken over by other compressors. If several compressors are needed to do this, addition is made
time-delayed. Load and total running times are stored for the individual compressors. The operating hours are
deleted, if required.

Connecting of compressors
is effected using the connecting moduls this being installed in the electrical housing of the compressor on the DIN-
rail. The connection to the Master control is made over the industry us RS 485 bus. The operating voltage of 24
volts AC/DC can be attached to the tension supply of the compressor. If a power supply of 24V AC or DC is
available from the compressor electric.

Compressor fault
If a compressor goes on fault the display shows a symbolic cross. On fault of reported compressor the performance
gets the compressed air consumption the most favorable compressors combination replaces through this one. The
fault report for the compressors is activated at the AIRTELLIGENCE PROVIS an common fault signal.
Faults from the connection modules will be given out over the digital output „General fault of external equipment.

Compressor motor running

If these inputs get connected, AIRTELLIGENCE PROVIS receives the motor running time. The total hours are also
stored as the load hours. The advertisement of the hours can be retrieved over the display. The running time
compensation provides equally running times of compressors with same capacity.

Compressor ready input

These input must be connected so that compressor management AIRTELLIGENCE PROVIS recognizes the
readiness of the compressors. If these input don't get connected, the compressor cannot be in operation. A fault
signal isn't activated.
der Kompressor nicht bereit und kann nicht angewählt werden. Eine Störmeldung wird nicht aktiviert.

If the fault input is not connected

and one of the compressors stops due to a malfunction, the display will show a wrong compressed air consumption
(too high = by the value of the faulty compressor). For this reason it is advisable to connect the malfunction signal
inputs, so that the compressed air consumption is always shown correctly and the capacity is also corrected and
immediately after reaching the P min.
 3

DISPLAY and KEY CONTROL

Pressure Air consumption

Analog input: AE2 AE3 AE4 on Master Modul

For indication of compressor symbols press button ▲

Function of analog inputs see Page 8

Button Function
E ENTER - open the Main menu
▲ Coursor upper
▼ Coursor lower
◄► Cursor right

+- und ◄► press simultaneos = Cursor left

E und ◄► Back to the Main picture

4 Showing status of compressors
7 Showing status of connection modules for external equipment
1 und ▲ More contrast of display
1 und ▼ Less contrast of display
1 Means YES (Y)
0 Means NO (N)
 4

Control and interpretation of regulated compressors

The various speed regulated compressor is integrated actively

The VSD compressor send the information about the motor speed over an analog output to AIRTELLIGENCE PROVIS. This
parameter must be programmed to the minimal and maximum capacity of the delivered compressed air. The analog output of
the VSD compressor have to be 4-20 mA. VSD Compressors with an analog output of 0-10 VDC must be changed from 0-10
VDC with a receiving multicoupler to 4-20 mA.

The pressure Setpoint of the VSD compressor must be centrically programmed

between the AIRTELLIGENCE PROVIS switch points.

Airtelligence PROVIS

The right combination of compressor capacities

together with speed regulated and normal compressors with a firm performance is decisive for good results in regulation. Is the
various speed regulated compressor the smallest in combination with only bigger compressors there are only small section regu-
lated by the various speed compressor. Big mechanical hurdle cannot be regulated directly.

Example of the right interpretation of the performances:

RIGHT combination WRONG combination

m³/min m³/min
45 45

36 36

27 27
20 m³/min

18 18

9 9

2,5-16 m³/min 10 m³/min 20 m³/min 2,5-16 m³/min 20 m³/min

0 0
0 9 18 27 36 45 0 9 18 27 36 45
Pmax Pmax

Pmin Pmin
 5

Configuration of regulation range and regulation buffer

Examble with a VSD Compresor with a regaulation range between 2,5 - 16 m³/min -

The free definable regulation range max

switches load/unload compressors ON and OFF within the pressure settings of AIRTELLIGENCE PROVIS. The regulati-
on limits are defined with the regulation range max and the regulation buffer. Is the regulation range max adjusted lower than
the maximum capacity of the VSD, the regulation range max and the regulation buffer will be activated.

Setting the "regulation range max"

Examble: the regulation range max will be programmed to 15 m of m³/min. If than the compressed air consumption is going
higher than 15 m³/min a time flexible trend calculation watches the compressed air consumption and switches another
compressor on (10 m ³/min like example). Within the pressure switch points of AIRTELLIGENCE PROVIS. If the speed's regu-
lated compressor reaches the regulation range max the second time together with the 10 m ³/min compressor at 25 m ³/min air
consumption again, the 10 m ²/min compressor will be replaced with the 20 m ³/min compressor directly.
The 10 m ³/min compressor will be switched on if air consumption reaches the regulation range max of the regulated compres-
sor at 35 m of ³/min together with the 20 m ³/min compressor.

Setting the "regulation buffer"

Examble: the regulation buffer will be programmed to 1,5 m³/min. If the compressed air consumption is getting lower and the
regulated compressor comes to the point "lower than 15 m³/min" together with the 10 and 20 m³/min compressor the regulation
buffer of 1,5 m³/min will be activated. The air consumption get again 1,5 m³/min lower a time flexible trend calculation stops the
10 m³/min compressor inside the adjusted pressure switch points at the AIRTELLIGENCE PROVIS. The VSD compressor
regualtes to the capacity of 13,5 m³/min.

Correct setting of regulation buffer Uncorrect setting of regulation buffer

Regulation range max = 15,0 m³/min Regulation range max = 15,0 m³/min
Regulation buffer = -1,5 m³/min Regulation buffer = -3,5 m³/min
Min compressor capacity = -2,5 m³/min Min compressor capacity = -2,5 m³/min
Control sum = 11,0 m³/min Control sum = 9,0 m³/min

Note:
- the regulation range max will be activ if the control sum is smaller than the capacity of the load/unload compressor
- the regualtion buffer is active if the controll sum is higher than the capacity of the load/unload compressor

The VSD compressor will be run in his best specific range.

regulation range Switch off with regulation buffer

max max max max max max
m³/min
buffer
buffer

buffer

36

27

18

6,6

2,5-16 m³/min 10 m³/min 20 m³/min

0
0 9 18 27 36 45 36 27 18 9 0
Pmax

Pmin
 6

Minimum flow rate and remote pressure supply

examble 4,5 m³/min examble 15 m³/min

Settings „minimum flow rate“ of variable speed compressor min max
minimized Regulation range
capacity m³/min
By setting the minimum capacity in the menu of the speed regulated 15

compressor can be determined whether or below the minimum delivery

amount of a normal compressor compressor in load / idle to run mode.
12
Setting the minimum flow rate of 0 m / min causes:
The speed controlled compressor is running in start / stop operation as long
as the consumption of compressed air is from 0 to 2.5 m³ / min.
8

Setting the minimum flow rate of 2.5 m³ / min causes:

Below 2.5 m³/min compressed air consumption a normall compressor is
running in a load / unload mode. The downshift is receding in consumption
2,5-16 m³/min 4
with a hysteresis

This mode is only economic if the air station with a small compressor as 2.5
to 4 m / min is installed in addition 0 4 8 12 16
0

Pmax

Pmin

Remote pressure supply through analog output at the RS-485 connection module

Pressure differences by dryers and filters

cause may be between the pressure
transmitter of the controlled compres- Capacity of regulated compressor
sor, and the master control rule up to
0.4 bar difference.
A precise control of pressure within very
close limits is not possible. The pressu-
re difference at the higher level control
must be expanded by the pressure
value can be set. This results in a pres- 0,4 bar
sure differential of 0.7 bar.
(More than at a station without a regula-
ted compressor)

With the remote control actual pressure value

ensure that the regulated compressor can be operated in conjunction with the master control in a narrow pressure limit.
The analog output of the connection module, deliver the current actual pressure of AIRTELLIGENCE PROVIS via 4-20 mA.
If the compressor pressure transmitter has an different range, than the output has to be adjusted accordingly.

Exemble:
AIRTELLIGENCE PROVIS 0-16 bar = 4-20 mA
Compressor 1-20 bar = 4-20 mA or Compressor -1-15 bar = 4-20 mA

An offset value setting for remote actual pressure

can be programmed via the menu of regulated compressor to the pressure setpoint of the controlled compressor to adjust the pres
sure difference.
This is especially important when more than 1 controlled compressor is installed in the compressed air network and the analog
values do not match the individual compressors
 7

Station with 2 variable speed compressors

In a station with 2 regulated compressors

the pressure transducer of regulated compressors in the same place as the pressure transmitter of the AIRTELLIGENCE PROVIS
feel, because differences in pressure of compressed air dryers and filters, the control behavior can influence each other greatly.
The configuration is described on page 4.

Settings „regulation range max“ und regulation buffer

exemble 1: 2 variable speed compressors with same capacity

compressor compressor type m³/min Regulation range max Regulation buffer Min. flow rate

1 Variable speed 5-30 28 m³/min 5 m³/min 0

2 Variable speed 5-30 28 m³/min 5 m³/min 0

3 load / unload 15 - - -

4 load / unload 25 - - -

exemble 2: 2 variable speed compressors with different capacities

compressor compressor type m³/min Regulation range max Regulation buffer Min. flow rate

1 Variable speed 1,5-10 9 m³/min 1,5 m³/min 0

2 Variable speed 5-20 18 m³/min 4 m³/min 0

3 load / unload 15 - - -

4 load / unload 25 - - -

In exemble 2
- if compressor 1 reach the regualation range max - it changes to compressor 2
- if compressor 2 reach the regualation range max - compressor 1 start again
- if both compressors reach the regulation gange max - one of th load / unload compressor will be started
- the controller decides, dependent of air consumption tha one of the regulated compressor can be switched off

The regulation range max

ensure that regulated compressors are always in the correct specific area. If an varaiable speed compressor delivers more air
than the setting of the regulation range max, the control started a flexible trend calculation to start the next load/unload compres-
sor. Dependent of the compressed air consumption.

Regulation range Downshift with regulation buffer

max max max max max max max max

regul. buffer

regul. buffer

regul. buffer
regul. buffer

15 m³/min

25 m³/min
5-30 m³/min 5-30 m³/min
 8

Programming load /unload compressors

Programming the compressor capacities

Press „E“ (Enter) to open the main menu.
Select the menu „programming
compressor control“ to program:
• Compressor module (capacities)
• Pressure switch points
• Compressor order of sequence
• Time cycle compressor order
• Control system parameter

Store data with „E“ (ENTER)

The compressor capacities

will be programmed in the menu
„Compressor Module“.
The capacities are definied in m³/min.

Analog inputs for compressors

If compressor capacity is selected,
-press „ENTER“ to go in the menu of
analog inputs for the compressor

Analog input AE 1
for connection of:
• CT-clamps
• kW-meter

Analog input AE 2
for connection of:
• Temperatur sonsor
• Universal sensor input
 9

Programming the variable speed compressors

Variable speed compressor:

Under VS (variable speed) select Y (YES)
for programming an various speed
compressor.
For load/unload compressors select N (NO).
Button „1“ means „J“ (YES)
Button „0“ means „N“ (NO).
• Set minimum capacity
• Set maximum capacity
• Press „E“ for confirmation

Press „E“ (ENTER) for configuration of

• analog output signal of inverter
• Regulation range
• Regulation buffer
• Minimum air flow

The minimum and maximum

• Capacity of various speed compressor
must be the same as from the
compressor manufacturer given data
• The mA of the inverter must be
programmed as it is in the minimum and
maximum speed of the compressor

Examble:
minimum capacity
2,5 m³/min = 6,2 mA measured
maximum capacity
16,0m³/min = 17,2 mA measured

Regulation range and regulation buffer

see Page 4+5
Analog input AE2:
programmable for following sensors
• Temperature
• CT-clamp
• kW-Meter

Analog output of connection module

Deliver the pressure signal of the master
control (see page 6) if average value
output setting is „N“.

Average output of pressure signal

If setting is programmed „Y“ the output
send the average pressure signal od
pressure settings.
Exemble: Pmin 6,0 bar, Pmax 7,0 bar
Average output = 6,5 bar
Note: If average value output is
programmed to „Y“ it belongs an another
connection module for the pressure signal
of the control.
 10

Programming - pressure and rank profiles

PRESSURE PROFILE
Menu „pressure switch points“.
4 different pressure profile can be
programmed. The pressure profile 2, 3,
and 4 can be selected over:
• real time clock
• digital input 1, 2 and 3

RANK PROFILES
Menu „compressor order of sequence“

Examble:
Follwing compressors shall be controlled
• compressor 1 with 20 m³/min
• compressor 2 with 18 m³/min
• compressor 3 with 18 m³/min
• compressor 4 with 13 m³/min
• compressor 5 with 10 m³/min
• compressor 6 with 10 m³/min

Special request
• Compressor 1 + 6 is connected to an heat
recovery
• Compressor 3 is very old, only for using
as standby compressor

Recommended programming
• compressor 1+6 rank 1
• compressor 2+4+5 rank 2
• compressor 3 rank 3

Compressors in the rank stage 1

will be controlled denpendent on air
consumption. If this is not enough, the
compressors of the rank 2
helps rank 1

Time cycle compressor order

In this menu equal hour for compressors
with the same capacity can be programmed.

Control system parameter:

changing of this settings only with
coordination by the manufacturer.

ATTENTION:
Only compressor on the same rank stage
will be controlled automaically by the
dependent airconsumption.
 11

Analog - Inputs of Master

ANALOG inputs on AIRTELLIGENCE PROVIS

AIRTELLIGENCE PROVIS has as
standart 4 analog inputs

Anlog input „AE1“

only for pressure transducer. The
pressure transducer extend the supply of
AIRTELLIGENCE PROVIS and is
includet. No other sensor should be
connected to the system. The pressure is
displayed in the display on the left head
line.
Analog input AE2, AE3, und AE4 can
be used for following sensors:
• Dew point
• Temperature
• Flow
• Extra pressure
• Current measuring
• Energy measuring

For each analog input

is an digital output available for alarm
signals

Programming of alarm signals:

• for minimum signal
• for maximum signal
can be programmed for each connected
analog sensor. The measurements of
these sensors are displayed permanently
in the footer line of the display.
.
Parameter setting of analog inputs
for examble:
• 4 mA upper data (Tmin)
• 20 mA lower data (Tmax)

The window for the alarm specification is

programmable vacant within the sensor values.
 12

ANALOG INPUTS of connection modules

ANALOG and DIGITAL inputs

Up to 8 connection modules can be
connected for external analog sensors
and digital potential free contacts of
dryers, condensate drains etc. The digital
signals can be used as fault or running
signals.

These modules get the number 17-24.

Address settings by the 8 DIP switches

Every connection module

has following out and inputs:

• 2 analog inputs for analog sensors with

4-20 mA Signal
• 3 digital inputs for fault an running signal
of external equipment
• 1 analog output 4-20 mA over the range
of the connected net pressure transducer
• 2 digital outputs (C-NO-NC 230VAC 2A)
for signal outputof connected analog
sensors (alarm set points)

Possible sensors for the analog inputs:

• Dewpoint
• Temperature
• Extra pressure
• Flow
• Current measurement
• Energy measurement

The 8 connection modules put up to

24 digital messages

and up to

16 analog inputs for sensors

 13

Digital input and Analog output on connection module

Configuration Flow Sensor

If a flow sensor connected to the analog
input, the value of Fmax is the maximum
measurable flow at 20 mA
The measurement of a flow sensor is, the
measured air speed in the compressed air
pipeline.
The definition is meters / second.
At the maximum air speed e.g. 185 m / sec
is applied to the analog output of flow sen-
sor 20 mA.
With a pipe diameter of 100mm are approxi-
mately 73 m³ / min flow

To the digital inputs of the connection module

can be connectted malfunction of refrigerant
dryers, filters, steam traps, oil-water separa-
tors, booster compressors, etc.
These inputs are defined as SMB disorder
(Y).
At fault is a fault signal to digital output 6 of
the master module is issued.
In the Web-server visualization an alert is
generated.
If these inputs are used as an operations
report must be programmed on that channel
on "Operation" with (J).

Analog output at the connection module

It is the actual pressure signal from the
AIRTELLIGENCE PROVIS as long as the
average output is in No (N) position. . (See
page 6)

Note: If average value output is program-

med to „Y“ it belongs an another connection
module for the pressure signal of the
control.
 14

PROGRAMMING REAL TIME CLOCK

The clock relay

permits following time controlled functions
• Switchung compressors ON/OFF
• 4 pressure profiles
• 4 rank profiles
• 2 digital outputs for relays to switch
ON/OFF additional equipment like
(Dryer, ball valves, etc.)

The dates for the 2nd, 3rd. and 4th

pressure profil and rank profil must be
configurated in the main menu

Note down all attitudes

for all program switching functions so that
no being missing programming arise

Switching bridge „CLOCK“

The real time clock is only activated over
the switching bridge generally.
Up to 16 switching points can be
programmed in the menu clock

Examble:
1. Monday to Friday from 6:00-22:00h
• Control system ON
• Pressure profil 1
• Rank profil 1
• Digital output R1 ON for dryer
2. Monday to Friday from 22:00-24:00 h
• Lower pressure with pressure profil 2 and
rang profil 2
• At the same time switching to a smaller
dryer switched by digital output R2
3. At 00:00 h
• The compressed air equipment is
switched OFF by the clock relay

Selected days with CAPITAL LETTERS

will be switched by the real time clock

Removing the switching bridge „CLOCK“

deactivated the clock relay functions.
The compressors management is
switching the compressors to the
• 1st pressure profile
• 1st rank profile
that is programmed in the basic menu
over the data of the 1st pressure and
1st rank profile.
 15

CLOCK - PROGRAMMING - NOTES

Compressor chanels
Nr. 1 2 3 4 5 6 7 8
Name
Nr. 9 10 11 12 13 14 15 16
Name

Pressure profile = PP
Nr. P min P max P Alarm
1 bar bar bar
2 bar bar bar
3 bar bar bar
4 bar bar bar

Compressor rank profile = RP

Kompr. 1 2 3 4 5 6 7 8
1.RF
2.RF
3.RF
4.RF

Clock relay switching times and functions

SP Day of the week Time LS PP RP R1 R2
1 M T M T F S S
2 M T M T F S S
3 M T M T F S S
4 M T M T F S S
5 M T M T F S S
6 M T M T F S S
7 M T M T F S S
8 M T M T F S S
9 M T M T F S S
10 M T M T F S S
11 M T M T F S S
12 M T M T F S S
13 M T M T F S S
14 M T M T F S S
15 M T M T F S S
16 M T M T F S S
SP=switching point LS=Management Leadsystem digital output =R1 digital output t= R2
 16

STATUS DATA

Status data
The following status data can be selected in
this menu:

• Compressor running times

• Deleting compressor running times
• Status of compressor modules
• Status of connecting modules for external
equipment

The running times of the compressors

• Load hours
• Total hours
The running hours are stored from the time
of operation with AIRTELLIGENCE PROVIS

Delete running times

It is possible to delete the running times of
all compressors. If the compressor running
times shall be deleted, put the value on "Y"
with the button "1" (YES) and confirm this
with „E“ (Enter)

Status of Compressor modules shows

• status of digital inputs
• Digital outputs
• Analog inputs
• Analog output

Press button 4

Status of connected analog modules shows

• fault or running signal of dryer, filter,
condensate drain etc.
• Analog value of connected sensors like
dewpoint, temperature etc.

Press button 7
 17

Display features

Display function
With different keys, the values of the con-
nected and programmed analog sensors
indicated the intended purpose

State of dew point sensors

+- 0 Press simultaneously

MM = Master Modul
AM = connection module

+- , Press simultaneously

+- 1 Press simultaneously

+- 2 Press simultaneously

+- 3 Press simultaneously

+- ▼ Press simultaneously

+- 6 Press simultaneously

+- 9 Press simultaneously

+- 5 Press simultaneously
 18

IP-address and Network settings

ATTENTION:
Before starting the Web-server, control the
date of AIRTELLIGENCE PROVIS and set
the clock to the current time
Step 1 activate programming bridge
Step 2 press simultaneously

+- 8

Program IP-address

ENTER CODE
Press button enter „E“

Set Code „000000“

IP-addresse program following parameter

• IP-Adresse
• Subnetzmaske
• Standartgateway

Communikation via Ethernet

The connection between AIRTELLIGENCE PRO-
VIS and the connection modules for compressors
and other components can be done via the
Ethernet by using the COM server.
The RS-485 interface AIRTELLIGENCE PROVIS is
connected to a COM server.
The COM server gets an IP address that matches
the IP address range.
More COM-server can be connected to the
Ethernet with different IP addresses.

Program waiting time for slave response

Press simultaneously
+- 9
ENTER CODE„111111“
Press Enter „E“

Program waiting time „200 ms“

If necessary changeable up to 250 ms

 19

COMMISSIONING and SWITCHING FUNCTIONS

Connecting -Modules
for compressors has to mounted on a DIN-rail in the electrical housing in of the compressor

The pressure switches of the compressors now become „safety pressure switches“. Examble:

Pressure setting of AIRTELLIGENCE PROVIS = 6,0 - 7,0 bar

Setting of compressor pressure switched = 6,5 - 7,5 bar

In case of absence of current, the contact’s of the connecting module are closed.
The compressors are controlled by their installed pressure switches

Check the pressure connection of the pressure tranducer

ATTENTION:
It is absolutely necessary to install the transducer at a calm part of the compressed air line.
As an optimum we recommend a seperate 1/2" line leading from the receiver to the tranducer.

Switching ON delay time is 30 sec (default by manufacturer).

Connect cable bridge START

with an cable or a switch. AIRTELLIGENCE PROVIS will start your compressed air station. From now on your
compressors are energy saving controlled and depending on your real consumption of compressed air.

Programming the various capacity of the various speed compressor

it is absolutely necessarily, to program the minimal and maximum capacity of the regulated compressor (according
to the manufacturer's indications) together with the mA values appropriately correctly.

Examble: minimum capacity = 2,5 m³/min = 6,2 mA measured

maximum capacity = 16,0 m³/min = 17,2 mA measured

please see the programming instructions

12. Switching functional description

Switching bridge: START

With this switching bridge the compressors will be switched ON / OFF.
Bridge activated = The compressors will be controlled by AIRTELLIGENCE PROVIS
Bridge deactivated = The compressors turn OFF

Switching bridge: PROG

If this is activated, all program parts can be programmed.
To programming the compressor capacities the switching bridge START may not be activated.

Switching bridge: CLOCK:

If this bridge is activated, the CLOCK will be activated. If this bridge is deactivated the compressor management is
switching the compressors now over the 1st pressure rank profile that is programmed in the basic menu.

Switching bridge: Manual:

If this bridge is activated, the compressors will be switched back to their own controller and will be controlled over the
pressure setting of the compressor controller.
20
 21

PART 2 Measurements, configuration and connection schematics

Page 22 Operating the housing

Page 23 Measurement of airtelligence PROVIS
Page 24 Connection and termina plan
Page 25 Connection scheme
Page 26 RS-485 connection scheme
Page 27 Connection module configuration and measurement
Page 28 Digital and analog inputs of connection module
Page 29 Compressor connection load / unload
Page 30 Compressor connection with remote / local function
Page 31 Analog inputs on connection module
Page 32 Analog output on connection module
Page 33 Digital IN and OUT on airtelligence PROVIS
Page 34 Analog IN and OUT on airtelligence PROVIS
22
Measurement of Airtelligence PROVIS 23
24
25
Airtelligence PROVIS

26
 72 mm

112 mm
27
28
29
30
31
32
 Airtelligence
Airtelligence PROVIS 33
Airtelligence PROVIS
34
 35

PART 3: OPTION: only if AIRTELLIGENCE PROVIS is built in metal housing

Page 37 AIRTELLIGENCE PROVIS in metal housing

Page 38 Power supply, key switches, RS-485
Page 39 Connection of analog inputs / outputs
Page 40 Connection digital outputs
Page 41 Connection digital inputs
Page 42 Part List
Page 43 Arrangement Diagram
36
Airtelligence PROVIS

37
38
39
40
41
42
43
 42

PART 4: Connection module Typ 4700 (grey)

Page 43 Configuration connection module

Page 44 Mesurement of connection module
Page 45 RS-485 connection scheme
44
Airtelligence PROVIS

45